Laser Light Module Lens Array With Sub-Lenses for Beam Alignment
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Solution Overview
Problem
Existing light emitting devices face challenges in achieving precise alignment and adjustment of light beams due to positional deviations of light emitting elements, leading to non-uniform beam diameters and diverging angles, which cannot be adequately corrected by conventional lens adjustments.
Innovation Solution
Incorporation of sub-lenses between light emitting elements and main lenses to individually adjust the position and orientation, allowing for precise alignment and correction of positional deviations, ensuring light beams meet target quality standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If only the tilt angle of the lens array is adjusted to compensate for mounting errors, then the parallelism of collimated light is improved, but the adjustment accuracy is insufficient to achieve target quality range
Solution Approach 1:
The patent divides the lens system into two independent parts: main lenses and sub-lenses. The main lenses are arranged in an array for bulk adjustment, while sub-lenses are individually positioned near each light emitting element. This segmentation allows independent adjustment of each sub-lens without affecting others, enabling precise compensation for mounting errors while maintaining overall system simplicity.
Solution Approach 2:
The patent adds a new dimension of adjustment by introducing sub-lenses that can be independently positioned in the optical path between the light emitting element and the main lens. This additional degree of freedom allows for fine-tuning of beam parameters beyond what single tilt angle adjustment can achieve, enabling accurate alignment while keeping the main lens array structure simple.
2Manufacturing precision
If sub-lenses are added to individually adjust each light emitting element, then the beam quality and alignment precision are improved, but the device complexity increases
Solution Approach 1:
The lens system is segmented into main lenses and sub-lenses with distinct functions. Main lenses handle bulk collimation and can be adjusted as an array, while sub-lenses handle individual element alignment. This functional segmentation improves manufacturing precision for each component while managing overall complexity through clear division of labor.
Solution Approach 2:
Each sub-lens is positioned close to its corresponding light emitting element and can be independently adjusted to compensate for that specific element's mounting errors. This self-service capability allows each element-lens pair to be optimized independently, achieving high alignment precision without requiring complex inter-dependent adjustment mechanisms.
3Stability of the object's composition
If the lens array tilt angle is adjusted to compensate for positional deviations, then the parallelism is improved, but the beam diameter uniformity and diverging angle consistency cannot be sufficiently corrected
Solution Approach 1:
The adjustment operation is segmented into two levels: coarse adjustment of the main lens array tilt angle for overall parallelism, and fine adjustment of individual sub-lenses for beam parameter uniformity. This segmentation makes the adjustment process systematic and manageable, improving beam parameter uniformity while keeping operations organized and straightforward.
Solution Approach 2:
The adjustment system operates in multiple dimensions: the main lens array provides global tilt adjustment in two angular dimensions, while sub-lenses provide local positioning adjustments in positional dimensions. This multi-dimensional adjustment capability achieves comprehensive beam parameter uniformity while maintaining operational simplicity through hierarchical control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The sub-lenses enable accurate collimation and convergence of light beams, maintaining uniformity and quality across different light emitting elements, even when they have varying properties or positional offsets.
Implementation Method 1
a first main lens to collimate or converge light emitted from the first light emitting element and a second main lens to collimate or converge light emitted from the second light emitting element
Implementation Method 2
a first sub-lens located in an optical path between the first light emitting element and the first main lens and a second sub-lens located in an optical path between the second light emitting element and the second lens
Data Source
AI summary
A light emitting device includes: a plurality of laser elements, each including a light emitting surface; one or more reflectors; a base including: a bottom portion on which the plurality of laser elements and the one or more reflectors are disposed, and a frame portion surrounding the plurality of laser elements in a top view; a cover attached to a top surface of the frame portion; and a lens array that is bonded to the top surface of the cover and includes: a plate-shaped portion, and a plurality of lens-shaped portions protruding upward from the plate-shaped portion, with the plurality of lens-shaped portions integrated into a one-piece body.